Insulated water-tight container

ABSTRACT

An insulated container for shipping, transporting, or storing warm or cold items is disclosed, useful for maintaining temperature of items stored or shipped within the container, the container assembly consisting of at least one layer of rigid or semi-rigid material, and at least one layer of flexible, thermally insulating, water-resistant material, in the form of a pouch, which pouch is secured to the rigid material at areas which allow easy reconfiguration of the container to form a finished container having desirable insulating and water-resistant characteristics.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of application Ser. No. 10/191,671,from which applicant claims priority.

TECHNICAL FIELD OF THE INVENTION

The present invention relates to an insulated container for shipping,transporting, or storing warm or cold items. More particularly, thepresent invention relates to a new thermally insulated containerassembly, which assembly is water-tight and thermally protective of itscontents, as well as insulated, so that container contents may bemaintained at constant temperature, while fluids or solids associatedwith the contents, if any, may be retained within the container duringstorage or shipment. The container assembly utilizes a layer of rigid orsemi-rigid material, and at least one layer of flexible, thermallyinsulating, reflective, water-tight material, in the form of a pouch orpocket, fastened to the rigid material in such fashion as to allow easyand inexpensive manufacture, and compact storage in a “knock down,”substantially flat, configuration. When desired, a user may quickly andconveniently manipulate the knock down assembly to create a volumewithin the container, thereby forming a finished container havingdesirable insulating and water-resistant characteristics in which theuser may keep or store warm or cold items with their associated fluids.

BACKGROUND ART OF THE INVENTION

In many insulated containers, rigid materials are combined withinsulating materials to form containers having insulating properties. Byuse of such containers, product suppliers may ship perishable productsrefrigerated or at room temperature, live or frozen, to customers whilecontrolling the environment in which the perishable products are placed,or while simply extending the useful life of such products before theyspoil. Examples of such uses for containers used in shipping include theshipment of fresh fish, in which a customer has requested that theproduct not be frozen, fresh flowers, around which a cool and moistenvironment should be maintained, and frozen tissues for research. Withall such products, maintenance of constant or low temperature will helppreserve freshness and quality of the products. Maintenance of constantor low temperature will also extend the useful life of the products, andoften thereby increase the distance over which such products may beshipped, as extending the time during which a product is preservedextends the time for shipment during which such product may reach itsdestination. In other insulated containers of this same generaldescription, the usefulness of the container is in preserving thetemperature of foods or beverages used in picnics, family outings, ballgames, and other recreational activities.

Containers of these types which have been successfully employed forthese purposes include insulated containers made from cardboard andindividual pieces of insulating material, such as Styrofoam or otherlightweight foam type insulation. These types of containers are oftenconstructed by gluing individual pieces of insulating foam material tothe interior surfaces of a cardboard container, which is formed as abox, or by inserting separate foam pieces to insulate each containersurface. While these containers offer advantageous high thermalresistance, cutting and gluing pieces of foam to construct the finishedcontainer requires substantial assembly time, with the result thatcontainers formed in this way are expensive to assemble, and are notwater tight.

Similar containers include insulated containers made of plastic foam,typically expanded polystyrene, formed in a mold to the desired shape.In some cases, additional corrugated pieces may be used to provideadditional structural support. While this type of container also offershigh thermal resistance and, in addition, ease of assembly, theresulting container is rigidly set in its final form at the time ofmanufacture. As a result, this type of container requires substantialfloor space and volume to store and transport prior to, during, andafter use. Moreover, expanded polystyrene is generally considered tohave a high impact on the environment as undesirable byproducts arereleased upon its manufacture and disposal. In addition, polystyrenedecomposes slowly, and, due to its airy and bulky nature, it occupies alarge volume in land-fill disposal sites.

Another type of container generally suited for shipment of perishableproducts consists of generally rigid walls made of corrugated cardboardor other suitable material, to which is bonded a flexible, sealable,insulative material having bubbles of gas entrapped therein to providethermal insulation. One form of such material is commonly referred to as“bubble wrap,” however rubber or plastic foam or other material havingthe characteristics described herein may be employed in the presentinvention. The flexible material may have a reflective surface, or anadditional layer of flexible reflective material, attached to the rigidwalls or flexible, sealable, insulative material, to increase thermallyresistant efficiency. While this type of container is well suited tosome applications, and has distinct advantages over other types ofinsulated containers, the containers of this type appearing in priorart, with the exception of one disclosed in a prior patent to thisinventor, do not allow for easy assembly by a user, with resultingsavings in time and costs. Nor, generally, are such containers in theprior art water-tight for retention of fluids, such as runoff frommelting ice, associated with the products shipped.

Finally, various apparatus and methods have been used in containerconstruction to preserve the contents within the container from breakageor degradation due to mechanical shock experienced while moving thecontainer. Such apparatus and methods include utilization of elastomericsheets secured to the interior of a hard-case carton, combinations offoam bodies and air sacs placed within the container, and variousinflatable mats, tubes, envelopes, and flaps. However, such apparatusand methods do not exhibit a knock-down, hard-shell, exterior, and apre-located and secured, interior pouch, thereby simultaneously alsoexhibiting water-tight, thermally-insulative, and shock-absorbingproperties.

It may be appreciated, in light of the foregoing discussion, that thereis a need for an environmentally friendly, affordable, insulatedcontainer, suitable for shipping perishable products, and suitable forproviding convenient temperature control, where the container is easy tomanufacture, thermally resistant, watertight, resistant to mechanicalshock, lightweight, compact prior to assembly, and easy to assemble by auser. The present invention is directed precisely to such usefulcharacteristics.

A number of schemes have been devised to accomplish one or more of thegoals set forth above. These schemes include single-piece and multi-partcontainers of cardboard, foam, and plastic flexible, sealable,insulative material materials. Various designs and configurations forsuch apparatus include:

U.S. Pat. No. 3,772,712 to Renn et al., which discloses a bag, the lowerportion of which is secured within the lower portion of a container.

U.S. Pat. No. 3,952,940 to Malcolm, which discloses a container forliquids formed of a paperboard carton and an inner tubular liner offlexible plastic film adhered to portions of the walls of the carton.

U.S. Pat. No. 3,957,195 to Lin, which discloses a container assemblycomposed of a plastic bag and a hollow paper body.

U.S. Pat. No. 4,030,603 to Angell, which discloses a method forpackaging fragile articles in which such articles are held by heattreat-shrink wrap within a frame and hard container.

U.S. Pat. No. 4,194,439 to Zimmermann, which discloses a method formaking a folded lined paperboard container and liquid proof liner havingan automatic bottom which locks in a set-up position when the containeris manipulated from a flat knock-down condition to a set-up position.

U.S. Pat. No. 4,235,065 to Freeman, which discloses a method forpackaging fragile articles in which an expandible tube is layeredbetween such articles, and then filled with gas and closed with a valve,thereby occupying space withing a container.

U.S. Pat. No. 4,262,801 to Avery, which discloses an apparatus havingflexible and outer container bodies having inflatable chambers whichhold articles placed there between.

U.S. Pat. No. 4,284,205 to Hirata, which discloses a pouch inserted in acylindrical shell to create a foldable cup.

U.S. Pat. No. 4,573,202 to Lee, which discloses an apparatus having anouter shell and an inner inflatable envelope.

U.S. Pat. No. 4,660,737 to Green et al., which discloses a packagingcontainer formed of a flexible pouch inserted in a closely form-fittingrelationship with an outer rigid carton.

U.S. Pat. No. 4,854,474 to Murray et al., which discloses a collapsible,self-standing, liquid-tight drinking cup formed of a plastic film linersecured to the inner surfaces of foldably interconnected paper-boardpanels.

U.S. Pat. No. 4,889,252 to Rockom et al., which discloses an insulatedcontainer formed of corrugated paperboard and a layer of flexiblematerial having air bubbles and foil.

U.S. Pat. No. 5,009,326 to Reaves et al., which discloses an insulatedmulti-part container of corrugated cardboard, folded and stapled to forman enclosure, with one-piece insulated liner.

U.S. Pat. No. 5,638,978 to Cadiente, which discloses an insulatedwaterproof container for the shipment of produce.

U.S. Pat. No. 6,296,134 to Cardinale, which discloses an insulatedwater-tight container consisting of at least one layer of rigid orsemi-rigid material, and at least one layer of flexible, thermallyinsulating, water-resistant material, in the form of a pouch secured tothe rigid material.

In the above-noted inventions, and in other prior art, cardboard, whenformed into a box, is a popular material in the shipping industrybecause it is inexpensive and relatively light weight when compared toits strength. As a result, insulated containers composed in part ofcardboard or paperboard help minimize shipping costs. However, cardboardalone is not suitable in those applications in which temperature shouldbe maintained within the container, and it is not suitable in thoseapplications where the contents of the container is a fluid, such aswater, or where fluid is important to preserving the contents. Priorefforts at achieving a suitable container for such purposes havetherefore focused on configurations and materials which have desirablecharacteristics when used in combination with cardboard, or which haveboth rigidity and such characteristics when used without cardboard.

As a result, various inventions of the prior art, such as those of theabove-noted patents, employ combinations of various insulatingmaterials, whether rigid or flexible, and water-tight or water-resistantlayers or barriers. A variety of insulating and water-resistant effectsmay be achieved where these materials are combined and formed asdirected by prior art. Thus, good insulative properties are achieved bycontainers utilizing preformed foam, however preformed foam does notallow compact storage, while foam sheets require expensive assembly andcannot achieve water-tightness. In the alternative, cardboard withflexible plastic bubble sheets may be easy to manufacture, however mostsuch arrangements are not water-tight, or are time consuming for a userto assemble if stored and shipped in compact, “knock down” form. Inaddition, the construction of such arrangements are somewhat expensivebecause multiple sheets are required.

The present invention is directed to combining these desirable featuresto achieve an insulated container suitable for shipment or storage of awide variety of products in the same container, notably perishableproducts. Accordingly, a single, low-cost container, may be utilized forwide variety of purposes, and at the same time have thosecharacteristics which make the container widely available, quicklyassembled, and easily employed. While the devices disclosed in priorpatents fulfill their respective objectives, prior patents andinventions do not describe or suggest an insulated, water-tight shippingcontainer, easy and inexpensive to manufacture, compact in storage andshipment, and quickly reformed by a user to produce the final containerhaving the desirable characteristics mentioned herein.

DISCLOSURE OF INVENTION Summary of the Invention

An insulated container utilizing corrugated cardboard or paperboard toachieve structural rigidity consists in its simplest form of thecardboard, an insulating material, and perhaps a means for resisting thetransmission of fluids or vapors through the cardboard. The insulatingmaterial is typically fastened to the cardboard, or simply placed withinthe cardboard carton after the cardboard is formed into an open box. Themeans for containing fluids or vapors, if present, may be placed insidethe insulating material, or between the insulating material and thecardboard. Padding or Styrofoam “peanuts” are often also used to cushionthe contents of the container against mechanical shock, and suchprotective systems may be employed with insulating and water-resistantmaterials in appropriate applications.

The present invention provides a new assembly, easy and inexpensive tomanufacture, and compact in its folded “knock down” configuration, inwhich configuration the assembly may be stored or shipped whileoccupying a minimum of space. The present invention is an assembly easyfor a user to quickly reconfigure into a insulated and water-tightcontainer, which container is suitable for storing or shipping productsrequiring a controlled temperature, and which container may also holdfluids and vapor found with the other contents of the container.

In one preferred embodiment of the present invention, an insulatedcontainer assembly is comprised of a rigid or semi-rigid outer containeror box, and a one-piece insulated liner in the form of a bag or pouch.The outer container may be composed of corrugated cardboard, paperboard,plastic, or other material having sufficient structural rigidity andstrength to satisfy the application at hand. Accordingly, corrugatedcardboard is the likely material of choice for an insulated containerdesigned to ship cut flowers, and for many other applications, whilecolored plastic might be more suitable to, and therefore chosen for, apicnic basket or sporting event beverage cooler application.

The outer container generally will include four sidewalls, a top and abottom, or flaps which form a top and a bottom when folded over theopening at the end of the container formed by the four sidewalls. Thetop or flaps are generally appended to the rigid or semi-rigid sidewallsof the container or, preferably, formed integrally with such side wallsin a single die-cut “blank.” If the container is formed in such a singleblank, the blank is then folded along preset fold lines to form thesidewalls, and at least two opposing edges of the blank are secured toone another with adhesive to form a tubular section of sidewalls, withclosure flaps extending from each end of the tubular section. The topand bottom flaps may consist of a single flap at each side of the blank,or more than one flap at each side of the blank, so that one or moreflaps are available for closure at the end of the tubular section whenthe sidewalls and tubular section are formed from the blank upon itsfolding. In the alternative, the blank may be cut without end flaps atone end, and separate top lid closure separately cut and supplied to theuser along with the side wall tubular section. The bottom flap or flaps(depending on the number of flaps utilized to close the bottom end ofthe tubular section) are affixed so as to form part of the bottomclosure. Thus, for instance, where a single flap is used to bridge thebottom opening of the tubular section, an area along its edge isattached to the opposing side of the tubular section. Where two flapsare used to bridge the bottom opening, the flaps are attached to eachother. In each case, at least two additional flaps affixed to adjacentsides of the tubular section are desirable to complete the closure atthe bottom of the tubular section.

The general nature of the invention being thus explained, it may beappreciated that confusion may arise in terminology as the details ofthe blank are described, along with the method of construction resultingin a finished container ready for use. To avoid such confusion, thefollowing terminology will be used:

The four portions of the die-cut blank which may be bounded on theirsides by fold or score lines (or an edge of the blank) when the blank isin lay flat form, which portions bear flaps and may be folded to createa tubular form, will be referred to as “side panels.” The same fourportions of the blank when folded, whether before or after expansion ofthe container, will be referred to as “sidewalls.” The exception to thisterminology is with reference to two of the opposing side panels amongthese four side panels, which opposing side panels are intended to bendto allow the container to expand and collapse when in use, and so have,as set forth more fully below, additional fold or score lines. Theseopposing side panels may also be referred to as “folding side panels”and the corresponding sidewalls in the expanded container may also bereferred to as “folding sidewalls.” The remaining two side panels, alsoopposing one another, but intended to move toward and away from oneanother during the process of expanding or collapsing the container, mayalso be referred to as “non-folding side panels,” and the correspondingsidewalls in the expanded container may also be referred to as“non-folding sidewalls.”

The edges of the side panels having appended top flaps, which edges forma single line when the blank is in lay flat form, will be referred to asthe “top” edges of the side panels, and the single line of such sidepanel top edges the “top” of the blank. Such top edges will also definethe “top” of the container when the blank is folded and the containerexpanded and ready for use; the top flaps comprise additional materialappended to the top edges of the side panels. The edges of the sidepanels having appended bottom flaps, which edges form a single line whenthe blank is in lay flat form, will be referred to as the “bottom” edgesof the side panels, and the single line of such side panel bottom edgesthe “bottom” of the blank. Such bottom edges will also define the“bottom” of the container when the blank is folded and the containerexpanded and ready for use; the bottom flaps comprise additionalmaterial appended to bottom edges of the side panels.

When the blank is in lay flat form, each side panel will have a “width”measured parallel to the top of the blank, such widths being equal tothe distance between the fold or score lines between panels (or betweena fold or score line and an end of the blank). The width of each top orbottom flap appended to each side panel will be measured consistently,i.e., parallel to the top of the blank. When the blank is in lay flatform, each side panel will have a “height” measured perpendicular to thetop of the blank, such heights being equal to the distance between thefold or score lines drawn between each side panel and its appended topand bottom flaps. The distance each flap extends from the side panel orsidewall to which it is appended will be the “length” of such flaps, andthe distal edge of each flap shall be its “end.”

As a result of the above terminology, when the side panels are foldedand the container constructed according to the present invention, thewidths of two side panels of the blank will equal the length of thesidewalls of the finished container, while the widths of the remaining(alternate) two side panels of the blank will equal the width of thesidewalls of the finished container. It may be appreciated, however,that if all such sidewall widths are not equal, the width of twoopposing sidewalls may correspond to the overall length of the expandedcontainer. As a further result of this terminology, when the side panelsare folded and the container constructed according to the presentinvention, the height of all side panels of the blank will equal theheight of the sidewalls of the finished container.

Continuing, the blank which will form the outer container of the presentinvention, prior to folding, may be cut so that all side panels are ofequal width, thereby creating a square when the expanded container isviewed from above (i.e., a square “footprint” for the expandedcontainer). However, a more usual configuration for the sidewalls of theexpanded container results when the blank is cut so as to form two widerside panels and two narrower side panels (all side panels remainingequal in height), thereby creating a rectangle when the expandedcontainer is viewed from above (i.e., a rectangular “footprint” for theexpanded container). As noted above, two of the side panels, thosecorresponding to the folding sidewalls, will generally have scores, orfold lines, extending the height of such side panels. The folding sidepanels will comprise at least alternate panels in the die-cut blank.Accordingly, such folding side panels will also be opposing sidewalls ofthe container in its expanded configuration. The scores or fold lines ofthe folding sidewalls generally extend from approximately the midpointof the top of each folding side panel, to approximately the midpoint ofthe bottom of the corresponding folding side panel. While these foldingside panels may be folded by a user without fold or score lines, thescore or fold lines of the folding side panels allows the folding sidepanels to be easily folded top to bottom, approximately in half, duringmanufacture, and the corresponding folding sidewalls to be easily foldedin the same way again after manufacture to expand or collapse thecontainer during use. Such folding results in movement of thenon-folding sidewalls toward each other, thereby collapsing thecontainer to its knock-down configuration. In containers having widerand narrower sidewalls, in a preferred embodiment, the scores and foldlines of the folding side panels are preferably formed in the narrowerside panels. However, the present invention also works well when thewider side panels bear scores or fold lines, and the present inventionspecifically includes such a configuration.

The bottom of the outer container of the present invention (in itsexpanded configuration) will, as noted above, usually comprise bottomflaps. The bottom flaps appended to the side panels are generally cut tocorrespond approximately in width to the width of such side panels.However, at least one such flap is also generally cut sufficiently longto meet or overlap the end of the corresponding flap appended to theopposing sidewall. That is, when the tubular section of side panels ismanipulated into its open, volume creating configuration, the flapsappended to two of the opposing sidewalls meet or overlap one another attheir distal ends when such flaps are folded toward one another. An areaof overlap for two such bottom flaps is important to the operation ofsome embodiments of the present invention, as such overlap provides anarea to apply adhesive or other fastening means so that the bottom flapsmay be affixed to one another (along their area of overlap). This areaof overlap is generally provided by forming the bottom flaps ofapproximately equal length, with the exception of one such bottom flapwhich is formed longer, its distal edge thereby extending further fromthe sidewall to which it is appended. However, other means for providingan area of overlap for two bottom flaps are easily envisioned, andwithin the scope of the present invention, as are other attachment meansfor bottom flaps when such flaps do not overlap.

When the bottom flaps are affixed to one another, one of the flaps maythen be folded against or along the edge of the other flap, therebyallowing the opposing, non-folding sidewalls to which the flaps areaffixed to approach each other. In this way the outer container may becollapsed to a knock-down configuration or, by reversing the movement ofthe opposing sidewalls, expanded to its open configuration, ready toreceive articles within the volume created thereby. While the sameflexibility between configurations may be achieved with a single flapappended to a bottom edge of one sidewall and extending to the bottomedge of the opposing sidewall (and affixed to an area adjacent to suchedge, the flap being folded approximately in half during collapse), thepreferred embodiments utilize two flaps as set forth herein.

The remaining flaps of the closure at the bottom of the container, thatis, the bottom flaps appended to the remaining folding sidewalls, may becut long or short. However, whether long or short, such flaps also bearscores or fold lines extending substantially their length, fromapproximately the midpoint of their line of intersection with asidewalls to approximately the midpoint of their distal edge. Such foldor score lines extend the fold or score lines impressed into theopposing folding sidewalls, thereby allowing these bottom flaps to bend,easily following the movement of the corresponding folding sidewalls asthese sidewalls are bent or straightened during manufacture or use.

It may be appreciated that, once the ends of the blank are affixed toone another to form the tubular section, the above system of (i) foldingalong the length of the two opposing folding sidewalls and (ii) foldingat least one bottom flap appended to the non-folding sidewalls, allowsthe container of the present invention to be collapsed around its“perimeter” (i.e. from folding sidewall to folded bottom flap toopposing sidewall) to its knock-down configuration. By simply reversingsuch folding, thereby straightening both the folding sidewalls and thebottom flaps, a user may expand the container to its full volume.

The top of the container may then be closed by the top flaps, or byseparate closure ususal in the industry, and sealed. In one such closureand sealing arrangement, the top may consist of four top flaps, two ofwhich bear cutouts for insertion of the ends or corners of the other twotop flaps, which top flaps may be scored for easy bending or folding.The top of the outer container, or the top flaps, may, in addition,feature a handle, or be capable of being formed into a handle, for easeof carrying the finished insulated container, or the outer container maycarry, separately from the top or flaps, a handle attached to itsexterior. It may also be noted that the folding sidewalls may be folded“outwardly,” so that the fold extends from the body of the (knockeddown) container, or the narrow sidewalls may be folded “inwardly,” sothat the fold extends within the body of the container in its knock downconfiguration.

The one-piece insulated liner of the present invention may be formedfrom one or more sheets of flexible, thermally insulative, waterproofand air tight material (the “pouch material”), or the liner may beformed from separate sheets having only one of these properties each. Inits simplest form, the material utilized to form the liner need only beair tight, so that the liner, once formed from such material into apouch as set forth below, may be water-tight when sealed at its top.Generally, however, both thermal insulation and waterproofing may bemost simply accomplished in a single sheet utilizing recently availableand inexpensive materials. One material of choice using currentlyavailable materials is a flexible plastic layer having at least onelayer of air bubbles entrapped therein (sometimes commonly known as“bubble wrap”) laminated to a layer of metalized polyester or foil.

This pouch material may be formed in a variety of ways, but is commonlyformed by bonding a first layer of smooth plastic to a second layer ofplastic having a surface with regularly spaced depressions pushed intoit. Upon bonding, the first and second layer adhere in areas in whichdepressions are not formed, while remaining separated layers at theareas of the depressions. The result of such bonding is entrapment ofair in the areas of the second layer in which the depressions wereformed. Alternate means for constructing pouch material incorporatebaffles between successive layers, which baffles comprise plastic“walls” between layers. The result of such construction is a materialhaving at least two layers, where the layers do not themselves contactone another, but only contact the walls extending between the layers.The insulative characteristics of such a layered construction areenhanced.

A pouch material having further enhanced thermal resistancecharacteristics may be obtained by constructing these materials in thepresence of an inert gas, or other gas having a lower heat transmissionrate than air. In such case, the bonded layers of the pouch materialthereafter holds the gas selected within the walls of the liner.Regardless of the gas or gas mixture utilized, a third layer of plasticis often bonded to the second layer of plastic in a fashion similar tothat set forth above, thereby further entrapping gas or gases betweenthe second and third plastic sheets. Further plastic sheets, creatingmore gas bubbles, may be added in this way to increase thermalresistivity. The multiple sheets after such fabrication together createa single, multi-layer sheet of pouch material. One or more of theindividual sheets of plastic comprising the pouch material may becomposed of a plastic having reflective properties, to thereby reduceheat transfer by radiation. In the alternative, another layer ofreflective plastic or other material may be attached to the pouchmaterial, or separately used with the pouch material to reduce heat lossby radiation.

Other configurations are possible based on similar water-tight andthermally insulative materials, such as those developed by BerkeleyLabs. Using such alternative materials, a gas may be injected into thewalls of the pouch through an open valve, and held within the liner bythe airtight material and the valve upon its closing. Alternatively, aportion of the pouch material may be composed of permeable elastomericmaterial, and the space within the walls of the liner injected with asmall amount of gas other than air, oxygen or nitrogen. Such other gasmay be selected from among a wide variety of gasses which have lowerdiffusion rate across the permeable material than air, gasses such ascarbon dioxide. Finally, its is also possible to construct the presentinvention utilizing multilayer plastic material wherein the layers,while holding a gas as in the preferred embodiment, are connected onlyat their edges. In such way, an inflatable pouch may be created whichexpands to surround and protects fragile materials after the pouch hasbeen inflated.

In one preferred embodiment of the present invention, a single sheet ofpouch material is simply cut into a rectangular shape, folded over once,and the cut edges matched. Some edges of the pouch material are thensealed, leaving unsealed those edges most distant from the fold line,thereby forming a pouch, with top opening away from the fold line, andbase of the pocket at the fold line. Alternatively, a single sheet maybe folded over after being cut, and sealed along a side adjacent to, andalong a side opposite to, the fold line.

A variety of means may be utilized to seal the pouch material, howeverthe sealing of edges to create a pouch may be quite easily accomplishedin one preferred embodiment by the application of heat to the areas tobe sealed as such areas are pressed together. The combination of heatand pressure causes the flexible plastic material to melt slightly,deflating bubbles incorporated into the material, and bonding togethersuccessive layers of plastic. Alternate means for sealing the edges toform a pouch include gluing, folding and sewing, or other meanscalculated to form a water-tight seal. The cutting and sealing asdescribed results in water-tight and insulative pocket, which may remainflat as originally folded and sealed or expanded to allow the insertionof cargo.

The plastic pouch material is cut to a width which, when so folded andsealed, will fit conveniently within the sidewalls of the outercontainer when the outer container is flattened into its knock downconfiguration. As so sized, the pouch material will also fitconveniently within the sidewalls of the outer container when it isexpanded to its final three dimensional shape, and may follow the sidewalls in such expansion if attached to them. The pouch material is alsocut to a length which, when so folded, sealed, and placed within theouter container, will extend through the outer container when it isflattened, and out the top and bottom of the flattened container(excluding flaps). When so placed within the outer container, the baseof the pocket of insulating material, at the fold line, extends belowthe bottom edges of the sidewalls of the outer container, while theopening of the pocket, away from the fold line, may extend past the topedges of the sidewalls of the outer container to allow ample material tooverlap or join the top edges of the pouch material to seal the pouchafter expanding and filling the container.

One variation on the construction of the pouch within the scope of thepresent invention includes the forming of cuts in the pouch materialextending from the top edge of the pouch a distance approximately equalto the length the pouch extends above the top of the sidewalls when thepouch is properly placed on the blank. Such cuts may be utilized toallow fastening of the material on either side of the cuts to the topend flaps, and so easy closure of the pouch when the top flaps arefolded to closure. Another variation on the construction of the pouchwithin the scope of the present invention includes using pouch materialwhich is inflatable after manufacture of the pouch. Such pouch materialmay be formed into a pouch and placed uninflated on the blank, andfastened to it, prior to constructing the tubular arrangement of thepresent invention. Once the tubular arrangement is formed and the bottomflaps fastened to each other or to the opposing wall as set forth below,the completed container may be shipped in its lay flat configuration,and the user may inflate the insulative pouch after the container isexpanded to its usable configuration. The inflatable pouch meeting thesecharacteristics must be specially designed with areas at each cornerwhere the pouch cannot be inflated, such areas then remaining uninflatedduring later expansion. Such corner areas are necessary to effectiveoperation of a pouch which may be later inflated by a user, as only bynot inflating corners can a pouch of this type fit and expand correctlyinto a hard container. It may be noted that pouch material having thisdescription is available, as is at least one finished pouch having thedesired characteristics.

In one preferred embodiment of the present invention, the distance thebase of the pocket of insulating material extends from the sidewalls ofthe container is approximately equal to or greater than one half thewidth of the narrowest sidewall. As a result, the pocket may be drawnopen to form a square or rectangle when viewed from either top orbottom, and the dimension of the resultant square or rectangle allowsthe pocket of insulating materials to approximately cover the areaoccupied by the outer container in its expanded configuration whenviewed from the top or the bottom. The distance the opening of thepocket of insulating material extends from the top flap fold line of thecontainer is also generally equal to or greater than one half the widthof the narrowest side wall. As a result, the top of the pocket hassufficient material to cover the area occupied by the bottom of theouter container, when viewed from the top or the bottom, in its expandedconfiguration. The top of the pocket also generally has sufficientmaterial to allow sealing of the top of the pocket, even in its expandedconfiguration, when the opening of the pocket of insulating materialextends from the top of the container a distance greater than one halfthe width of the narrowest side wall.

A means for attaching the pouch to the blank, or to the interior of thetubular section of the outer container, is generally utilized in thepresent invention, generally in the form of an adhesive. The attachmentmeans, when used, is located on both sides of the pouch in one preferredembodiment, along lines at a distance from the edges of the pouch ofjust over one-half the width of the folding sidewalls of the container.When the pouch is properly placed on the blank during construction, theadhesive may be applied to the pouch along such lines on the pouch, oralong the areas of the non-folding side panels near their edges (i.e.,near the “corners” of the outer container once the side panels arefolded and the container expanded), or along each of these areas. Theseare the primary areas for attachment between the pocket and the outercontainer. In one embodiment of the present the invention the pocketmust be attached in this fashion, at or near both side edges, to allfour corners of the outer container (when expanded), near the fold linesat the intersection of the sidewalls. The attachment between the pocketand sidewalls is accomplished preferably by adhesive placed between thematerial of the pocket and the area adjacent the edges of the widersidewalls, however the means for attachment of the insulating materialto the corners of the outer container may be glue, tape, a combinationof glue and separable tape of the “velcro” type, or by any other meanswhich does not pierce the pouch material, or cause unequal strain at anypoint in the material. Methods of attachment which allow for removal ofthe insulated pocket from the outer container have the additionaladvantage of allowing cleaning of the pocket after separation from thecardboard, thereby preserving the structural integrity of the cardboardagainst weakening by contact with water, and recycling the outercontainer and insulative pocket separately.

It should be specifically noted here that, while the adhesive or otherattachment means set forth above assists in maintaining the pouch in itsproper position within the outer container, and assists expansion of thepouch when the outer container is expanded, attachment means is notnecessary to all embodiments of the present invention. In someembodiments the pouch may simply reside within the tubular section ofthe outer container during shipment, and the pouch will expand withinthe outer container during use, both by action of the sidewalls againstthe pouch, and by action of the contents of the pouch as such contentsrequire volume within the pouch when placed within it.

Once the tubular assembly with folded bottom and attached pouch areconstructed according to the apparatus set forth herein, a user wishingto employ the present invention may, as noted more fully below inrelation to the method of the present invention, simply grasp thetubular assembly, manipulate it to expand the assembly by moving thenon-folding side panels apart, and lock the assembly in its expandedconfiguration by locking the folding side panel bottom flaps into thenon-folding side panel flaps, by taping or gluing the bottom flaps toeach other or to the side walls of the now expanded container, or byother appropriate means. In its expanded configuration, the assembly ofthe present invention is open to accept articles for shipment orcarrying, closed at the bottom, capable of closure at the top by meansof top flaps and excess material at the top of the pocket, and, once soclosed, a container having an exterior hard shell, and a water-tightinterior pouch resistant to transfer of heat into or out of thecontainer.

The manufacture of the present invention involves a series of steps,beginning with the cutting of a blank for the tubular assembly from arigid or semi-rigid material. In such manufacture, a measure of suchmaterial sufficient to create the finished product is cut to create aflat blank having the requisite side panels and flaps. The blank may bescored or pressed along appropriate lines during cutting to create thescores or fold lines of the blank of the present invention, or suchscoring or pressing may take place before or after such cutting of theblank. A measure of insulative and water-tight material sufficient insize to create a pocket or pouch of appropriate size is also cut,folded, and sealed along at least two sides (leaving open at least oneside). The pocket is, once formed, placed at the correct position on theblank, or upon adhesive residing on the blank, or adhesive is applied tothe pocket and then the pocket is placed at the correct position uponthe blank. The blank is then folded over the pocket and the edges at theends of the blank affixed to one another by additional adhesive or othersuitable means. Finally, the distal edge of at least one flap of thenon-folding side panels is folded over the edge of the opposingnon-folding side panel, or over the distal edge of the opposing flap ofthe opposing non-folding side panel, and fastened in such position tocreate a folded bottom for the container. In the alternative, adhesivemay be applied to the correct positions on the pocket, or the interiorof the tubular section once formed, and the pocket then placed in thecorrect position within the tubular section, and the tubular sectionthen collapsed to its knock-down configuration. While these methods ofconstruction are stated somewhat generally to provide guidance on theoverall process, the preferred method proceeds more specifically asfollows:

Starting with a measure of rigid or semi-rigid material, a blank is cutin a shape which, in one embodiment of the present invention, hasmaterial sufficient to form four side panels for creating the sidewallsof the present container once constructed, at least one bottom flap atone side of the blank for forming a closure at the bottom of thecontainer once constructed, and at least one top flap at the other sideof the blank for forming a closure at the tope of the container onceconstructed. The bottom flaps are formed of unequal length in onepreferred embodiment, the longer bottom flap appended to a non-foldingside panel residing between two folding side panels. The blank is alsocut to form an end tab at one end of the blank in one preferredembodiment, the end tab usable for affixing one end of the blank to theother end of the blank using adhesive or other suitable means, therebycreating the tubular construction of the container. Before the blank iscut, or in the blank itself as or after it is formed, a number of foldlines or score lines are impressed in the material of the blank, whichfold lines define the four side panels, the top flap or flaps, thebottom flaps or flaps, and the end tab. These fold or score lines allowthe blank to bend easily between the side panels to create the foursidewalls, to create the top and bottom flaps for closure, and to createthe end tab for forming the tubular assembly when the end tab is affixedto the area near the edge of the opposing end of the blank. Twoadditional fold or score lines are impressed the length of each foldingside panel, along the mid line of each such panel. An additional fold orscore line is, in one embodiment of the present invention, impressedalong a line near the distal edge of the longer bottom flap, for easybending of that bottom flap once the tubular assembly is formed, and thebottom flaps affixed to one another using attachment means as set forthbelow.

Starting again with a measure of flexible, thermally insulative,waterproof and air tight “pouch material,” in one preferred embodiment asheet of such material is cut in the proper shape and size to “fit” theblank. More specifically, the sheet is generally cut in a rectangularshape with a width such that, if the sheet is centered on a non-foldingside panel of the rigid blank, the sheet will extend beyond the sideedges of that side panel (i.e, beyond the fold or score lines betweenside panels) a distance of about one-half the width of the folding sidepanels. The sheet of pouch material is also cut with a length such that,if the sheet is centered on a non-folding side panel of the blank, thesheet, if folded in half, will also extend beyond the bottom edge ofthat side panel (i.e., beyond the fold or score line between that sidepanel and the bottom flaps) a distance of about one-half the width ofthe folding side panels, and beyond the top edge of that panel (i.e.,beyond the fold or score line between that non-folding side panel andthe top flap or flaps) a distance of at least one-half the width of thefolding side panels.

Once cut, the measure of pouch material is generally folded in half uponitself, the edges and ends matched, and the material sealed along itstwo side edges. Such sealing creates a pouch or pocket in lay flat formcomprised of two sides of flexible pouch material, a fold line betweenthe sides of the pouch at its bottom, two sealed side edges, the sideedges often showing seal or melt lines where the material is sealed toitself along the edges, and one open end at the unsealed edges acrossfrom the fold line. While somewhat less convenient and more bulky, thepouch may also be formed from two separate pieces which together havedimensions approximately equal to the single measure noted above. Suchseparate pieces may be joined along three edges to create the lay flatpouch with one open end required by the present invention.

Whether formed of a single piece in the preferred embodiment or from twoseparate pieces, the corners of the pocket adjacent the fold line of thepocket, once formed, may be cut to reduce bulk, and then resealed toregain water-tight and thermal properties. The angle and amount of suchcut corner cutting may vary, however the preferred angle of cut is about45 degrees, and the preferred distance of such cut from the corner ofthe pouch prior to cutting should be a distance of about one-half thewidth of the folding side panels of the rigid cut blank. While thecorners of the pouch may be cut to reduce bulk in some applications, thepreferred embodiment is to leave the corners, which may be easily foldedinto the container or under the flaps at the bottom of the containerduring expansion. The material of the corners may also be simply kepttogether by melting it near the line where the corners might be cut insome embodiments, or melting all the material of the corners of thepouch.

Returning to the flat blank cut from rigid or semi-rigid material, ameans for attaching the end of the blank or, in the preferredembodiment, end tab (or tabs) of the blank, is secured to the end of theblank or end tab. As a result, the end tab may be affixed by suchattachment means to the area near the edge of the opposing end of theblank, to thereby create a tubular shape from the blank. In a similarway, means for attaching the bottom flaps to one another is secured toat least one bottom flap, near its distal edge. As a result, one bottomflap may be affixed by such attachment means to the opposing,non-folding side panel or, in a preferred embodiment, to the opposingbottom flap. Other attachment means may be secured to both non-foldingside panels at least along the areas close to the edges of such sidepanels. While the areas to which attachment means, when used, aresecured may be fairly narrow, a wider placement of such attachment meansresults in a fuller connection between the pocket and the blank, andultimately a smoother interior compartment within the pocket once thecontainer is opened to its expanded configuration. In addition, theadhesive or other means of attachment of the pouch to the blank, whenused, may be such as to allow removal of the pouch from the containerfor separate disposal or recycling of the pouch and outer container, orthe means for attachment in some applications may be durable to keep thepouch securely within the outer container.

Of course, the steps in the process of the present invention may bereversed in that the attachment means secured to the end tab, bottomflaps, and side panels may be secured to the flat blank prior toformation of the pouch as set forth above, or these steps may be takenin any order (as noted below, attachment means may also be applied tothe end tab, bottom flaps, and side panels either before placing thepouch onto the rigid blank or afterwards).

After the rigid or semi-rigid blank is properly cut, and attachmentmeans secured to at least one end tab and bottom flap as set forthabove, and after the pouch or pocket of the present invention has beenformed from the pouch material has been formed by cutting, folding, andsealing as set forth above, the pocket may then be joined with theblank, and attached to it using the attachment means secured to theblank. This is accomplished in one preferred embodiment by placing thepocket on the blank, and on the attachment means on the non-folding sidepanels of the blank, so that the pocket is approximately centered oversuch side panel between two folding side panels, such that the sealedside edges of the pocket extend across the fold or score lines betweenthe non-folding side panel and each folding side panel, and furtheracross about one-half the width of each such folding side panel. In suchposition, the edges of the pocket extend approximately up to the fold orscore line running the length of each folding side panel. In itspositioning, the pocket is also placed on the blank as set forth abovein a position such that the bottom of the pocket, at the pocket foldline, extends from the bottom edge of the non-folding side panel andacross most of the length of the longer bottom flap appended to thatside wall (i.e., almost to its distal edge). In such position, thebottom edge of the pocket then extends approximately up to the fold orscore line near the distal edge of the longer bottom flap, a distance ofapproximately one-half the width of the folding side panels. In suchposition, finally, the top edges of the pocket forming its open end alsoextend beyond the top edge of the non-folding side panel, and across thetop flap attached to that panel, a distance of at least one half thewidth of the folding side panels.

Once in position on the blank, the pocket may be simply pressed intocontact with the attachment means residing along the edges of thenon-folding side panel of the blank, to thereby attach the pocket to theblank near such edges, or attach the pocket to a larger area of thewider side panel of the blank wherever the attachment means has beenapplied to the side panel (as set forth above). In the alternative, thepocket may simply reside in the proper position without attachmentmeans, and the process of construction may continue (as set forthbelow).

After the pocket is positioned correctly on the blank and attached tothe blank using the procedure set forth above, a user may then easilyfold one-half of one folding side panel, at the fold line of that panel,over a side edge of the pocket and across the body of the pocket, theuser thereby folding the end of the blank over the pocket near its edgea distance equal to about one-half the width of the folding side panel.At the other side of the pocket, a user may also easily fold one-half ofthe other folding side panel, along with the remainder of the blank, atthe fold line of the folding side panel, across the other side edge ofthe pocket and across the body of the pocket. The user thereby folds theother end of the blank over the pocket near its second edge a distanceequal to about the width of the wider side panel plus about one-half thewidth of the narrower side panel. Of course, the order of folding of thefolding side panels over the pocket as set forth above may be reversedwith the same overall result.

When each end of the blank has been folded as set forth above, the endsof the blank, or the end tab at one end of the blank and the other endof the blank in the preferred embodiment, or end tabs at each end of theblank, may overlap. Since the ends of the blank, or the end tab at theend of the blank, bear attachment means applied previously as set forthabove, construction continues when the ends of the blank, or one or moreend tabs at the ends of the blank, overlap, by pressing the ends of theblank, or such end tab and other end of the blank, together. This bringsone end of the blank into contact with the attachment means residingalong the edge of the other end of the blank, or the end tab, intocontact with the attachment means residing along the other end of theblank, thereby securely fastening the ends of the blank together tocreate a (flattened) tubular arrangement of both wide and narrow sidepanels (with flaps). Since the pocket of the present invention wasappropriately placed on the blank, and fastened to it via appropriatelyplaced attachment means prior to folding the blank in at least onepreferred embodiment, the tubular arrangement of side panels, oncefolded as set forth above, has within it the previously positionedpocket. Since the pocket of the present invention was placed on onenon-folding side panel of the blank prior to folding the blank, andsince attachment means was appropriately placed on the other non-foldingside panel of the blank prior to folding the blank in at least onepreferred embodiment, both non-folding side panels of the tubulararrangement of side panels, once folded as set forth above, may besecurely attached to the pocket by the attachment means. As a result,the tubular arrangement of side panels after folding has within it, andsecurely attached to it in some preferred embodiments, the previouslyplaced pocket. If attachment means is used, the areas of attachment ofthe pocket to the side panels correspond to the area on the non-foldingside panels to which attachment means was previously applied. It shouldbe noted that the order of steps in applying the attachment means to theappropriate places to secure the pouch to the blank during construction,of attachment means is used, may be reversed. That is, the attachmentmeans may be applied to the end tab, bottom flaps, and side panelseither before placing the pouch onto the rigid blank or afterwards, orin any order, and the attachment means may be applied to either suchareas on the blank, or on corresponding areas of the pouch, or bothprior, to bringing the pouch and blank together.

After the pocket is positioned correctly on the blank and attached tothe blank (in one embodiment) using the procedure set forth above, andthe ends of the blank attached to one another as set forth above, a usermay then easily fold the edge of the longer bottom flap (appended to oneof the non-folding side panels), at the fold line at the distal end ofthat flap, over the edge of the opposing bottom flap. When the longerbottom flap has been folded as set forth above, the distal edges of theflaps of the non-folding side panels may overlap. Since the area nearone or both distal edges of such bottom flaps bear attachment meansapplied as set forth above, construction continues when such bottomflaps overlap by pressing the areas having such attachment meanstogether. This brings one area of one bottom flap into contact with theattachment means residing along the area of the opposing bottom flap,thereby securely fasten the distal ends of the bottom flaps together tocreate a folded bottom end for the tubular assembly. Of course, theorder of folding of the bottom flaps to create the folded bottom end forthe tubular assembly may be reversed without changing the end product,i.e. a tubular assembly, with folded bottom end, and attached pocketwithin.

As an alternative to the above procedure, for constructing the containerof the present invention, the pocket of insulating material may beinserted into the outer container once it has been folded to a tubularassembly, with end tab, opposing blank edge, and bottom flaps secured asabove. While not as desirable for a number of reasons, such a proceduremay be utilized when a slow set adhesive or other means is used tofasten the pouch to the interior of the tubular section, or when thepocket and outer container are to be constructed without attachmentmeans between them. In such procedure, the pouch is again positioned sothat opposite edges at the sides of the pouch extend into the folds ofthe folding sidewalls of the container, with such edges adjacent thefold lines of such sidewalls. Further, the base of the pouch ispositioned so that the fold line at its base extends into the foldedbottom created by the bottom flaps when the container is in its knockdown position. Once the pocket is in position within the sidewalls ofthe container, the pocket is attached to the sidewalls near the edges ofthe corresponding non-folding sidewalls of the outer container as beforein those embodiments utilizing attachment means between pouch and outercontainer.

As a result of manufacture in the method described herein, the presentinvention, as noted above, may be incorporated into an insulatedcontainer assembly which is capable of being folded flat, with sidewalls of the outside container in the knock down configuration, and withthe flattened flexible, sealable, insulative material of the pocketresiding within the side walls. To utilize the present invention, a usermay select a flattened container of appropriate size, and manipulate theouter container to expand it in the manner set forth herein. Upon suchexpansion, the flexible, sealable, insulating pocket of one version ofthe present invention is pulled along with the (non-folding) side wallsof the outer container, thereby filling the volume created upon itsexpansion. At the top of the box, the opening of the pocket opensnaturally when the outer container is expanded, thereby allowingplacement of articles within the pocket and the outer container. At thebottom of the outer container, the bottom of the pocket is reformed asthe corners of the outer container, at the fold lines between sidewalls, pull the opposing sides of the pocket away from each other. Atthe same time, and in response to such pulling, the sealed edges of thepocket are pulled inward, in one preferred embodiment, toward the mainbody of the pocket.

The user continues to expand the outer container until it reaches apoint at which the sidewalls are perpendicularly oriented to theiradjoining sidewalls, and the bottom or bottom flaps may be manipulatedinto position to close the outer container at its bottom. At the pointof maximum expansion of the outer container, the insulated pocket isreformed so that the pouch material runs substantially all around theinside of the sidewalls, and extends from the top of the container.Meanwhile, as the outer container is opened, the sealed side edges ofthe pouch near the midline of the folding sidewalls of the outsidecontainer are drawn toward the center of the container, as is the foldline of the pouch at the bottom of the container.

At full expansion of the outer container, the bottom of the outercontainer formed by the joined flaps of the non-folding sidewalls formsa substantially flat surface. The remaining flaps (i.e., the flaps ofthe folding sidewalls) may then be easily folded over the bottom of theouter container, and secured in place by appropriate means. Such foldingover the bottom of the container will also generally result in foldingthe flaps of the folding sidewalls over the exposed bottom corners ofthe inner pouch, which normally project from the interior of the containout between the folding sidewalls and the now straightened flaps of thenon-folding sidewalls. In a rectangular “J lock” bottom box design, thebottom closure is normally accomplished when the flaps of the foldingsidewalls are folded around the bottom of the container after expansion,and folded into and locked into place in slots formed in the flaps ofthe non-folding sidewalls. Closure of the pocket at its top then mayproceed by folding the pocket material, and securing it in place, orotherwise securing the ends of the pocket material to form a closure.Such closure may be accomplished in a variety of ways currently in use,including use of a “lip & tape” (or lip with adhesive, or pressuresensitive tape) design, with or without folding the edges of the openingto achieve tighter closure. In most cases the pouch material, securednear the edges of the pocket opening, are used to close the pocket uponfolding. However, a preferred method of closure in the commercialshipping market is through use of a continuous rotary sealer or heatsealer in which a user may apply, generally by hand, both pressure andheat to melt the edges of the pocket opening together. By such means, auser may create a pocket having water-tight characteristics even if thecontainer as a whole is upended during shipment. Upon completing theclosure of the pocket, the user may close the outer container in the waydictated by the design of the outer container.

By the above process, the user may store the insulated and water-tightcontainer assembly in its knock down configuration pending use, selectand quickly manipulate assembly to reconfigure the assembly to its finalexpanded shape, and secure the assembly in such final shape, ready toreceive articles. The reconfiguration process is both quick andconvenient for the user, and the resultant container inexpensive andreadily available. Further, by means of the present invention, amanufacturer may quickly and inexpensively provide a light weight,durable, insulated, and water-tight container which may be manipulatedinto its final shape by the user, and store and ship such assembly usinga minimum of space and cost.

The more important features of the invention have thus been outlined,rather broadly, so that the detailed description thereof that followsmay be better understood, and in order that the present contribution tothe art may be better appreciated. Additional features of specificembodiments of the invention will be described below. However, beforeexplaining preferred embodiments of the invention in detail, it may benoted briefly that the present invention substantially departs frompre-existing designs of the prior art, and in so doing provides themanufacturer and distributer with the highly desirable ability to easilyand inexpensively manufacture the new assembly in a compact, folded“knock down” configuration, and store or ship the assembly in suchconfiguration while occupying a minimum of space. The design of thepresent invention has distinct advantages over prior art. Thus, theassembly of the present invention provides an assembly easy for a userto quickly reconfigure into a insulated and water-tight container, whichcontainer is suitable for storing or shipping products such as flowers,fruits, beverages, or other products requiring a controlled temperature.It also allows the insulated container incorporating the design to holdfluids and vapor within the container thereby increasing insulativeproperties of the container, while preventing fluids from leakingthrough the container with resultant mess and loss of structuralintegrity. It also provides a water-tight or water-resistant liner in acollapsible, structurally rigid exterior, for space saving storage ofthermally sensitive contents and any associated fluids. Accordingly,this water-tight container design satisfies airline cargo regulationsrelating to shipping with water and ice, and melted ice runoffcontainment. The rigid exterior of the present invention may itself bemanufactured with water resistant adhesives for durability andreusability. Finally, the assembly of the present invention is designedand composed of such materials that it utilizes less material overall inconstruction and, eventually, disposal, without the use ofcloroflorohydrocarbons (CFCs), while the construction of the assemblyallows reuse. Accordingly, the assembly is less environmentallyburdensome.

These consequences arising by use of the present invention result insubstantial savings in user time, and substantial savings in expense inmanufacture and distribution, and reduction in storage area until theuser determines that a container having the characteristics noted hereinare required, at which point the insulated container system of thepresent invention is simply applied to the task at hand.

OBJECTS OF THE INVENTION

The principal object of the present invention is to provide a newinsulated container assembly for use in transporting temperaturesensitive goods, with the additional characteristic of providing a meansfor retaining fluids and vapors within the container.

A further object of the present invention is to provide an insulatedcontainer assembly which may be inexpensively and easily manufacturedutilizing standard, readily available materials.

A further object of the present invention is to provide an insulatedcontainer assembly which may be transported and stored when not in usein a flattened configuration, thereby preserving space and reducingtransportation and storage costs.

A further object of the present invention is to provide an insulatedcontainer assembly which is quickly and easily expanded by a user fromits folded configuration to its configuration when in use.

A further object of the present invention is to eliminate the need forvoluminous, rigid, three dimensional insulating liners which must becarried separately, and placed in position within a container after ithas been expanded.

A further object of the present invention is to provide consumers with aconvenient, more environmentally sound option to the disposable coolerscurrently constructed of expanded polystyrene foam.

A further object of the present invention is to provide an insulated,water-tight container utilizing an interior pouch of standard size whichmay be fitted to a rigid outer container of varying dimensions.

BRIEF DESCRIPTION OF DRAWINGS

The invention will be better understood and objects other than those setforth above will become apparent when consideration is given to thefollowing detailed description thereof. Such description makes referenceto the annexed drawings wherein:

FIG. 1 is a top-side perspective view of a flexible plastic layer havingat least one layer of air bubbles entrapped therein laminated to a layerof metalized polyester or foil.

FIG. 2 is a top-side perspective view of the flexible plastic layer ofFIG. 1, in which the layer has been folded once, and the edges matchedand sealed after folding to create a pouch. In FIG. 2 the corners of thepouch near the fold line have been cut and resealed to reduce bulk.

FIG. 3 is a plan view of a rigid or semi-rigid outer container cut blankprior to assembly, and showing preferred areas for application ofadhesive or other attachment means, apparent fold lines, and insertionpoints for joining bottom flaps after expansion.

FIG. 4 is a top-side perspective view of the rigid outer container ofFIG. 3, upon which the pouch or pocket of the present invention has beenplace, and affixed in its preferred position by contact of the pouchwith the attachment means appearing in the preferred areas of FIG. 3.

FIG. 5 is a top-side perspective view of the rigid outer container ofFIG. 4, in which the side panels of the blank have been folded towardeach other over the pouch, and the end tab at one end of the blank, withits attachment means, placed in contact with the other end of the blankand affixed thereto using the attachment means, thereby creating thetubular arrangement of sidewalls. Prior to completion of construction,FIG. 5 shows the bottom flaps appended to the wider sidewalls in unequalwidth, prior to folding of one bottom flap over the other to create thebottom, and FIG. 5 also shows each narrower sidewall in foldedconfiguration prior to expansion of the container.

FIG. 6 shows the same top-side perspective view of FIG. 5, still inknock down configuration, but with one bottom flap of one of the widersidewalls now affixed to the other bottom flap of the other widersidewall along the area near their distal edges, thereby creating abottom for the container.

FIG. 7 is a perspective view of the bottom of the rigid outer containerof FIGS. 5 and 6, in which the outer container and the flexible plasticpouch of the preceding figures have been expanded to create a volumeinto which objects may be placed. When so viewed from the bottom, thebottom flaps, which have been affixed to each other near their distaledges, have unfolded to create a bottom for the container while thecontainer expands. At the same time the pouch affixed to the interior ofthe container sidewalls has also expanded.

FIG. 8 is a top-side perspective view of a the rigid outer container ofFIG. 7, wherein the flexible plastic pouch has followed the side wallsof the outer container in its expansion, thereby opening the interior ofthe pouch to receive objects, with the free top edges of the pouchextending beyond the body of the container to allow closure of the pouchwith the material so extending.

FIG. 9 is a flow chart diagram of the process of manufacturing thepresent invention from rigid or semi-rigid material (to form the blank),and flexible, waterproof, air-tight, and insulated material (to form thepouch or pocket).

DESCRIPTION OF A FIRST PREFERRED EMBODIMENT

Referring initially to FIG. 1, a flexible plastic layer 5 having atleast one layer of air bubbles entrapped therein laminated to a layer ofmetalized polyester or foil (sometimes commonly known as “bubble wrap”)is shown. The layer 5 has edges 11 at each end, edges 12 along each sideof the layer.

In FIG. 2, the flexible plastic layer 5 of FIG. 1 is shown folded midwayalong fold line 13, end edges 11 have been matched with each other, andside edges 12 have been matched with themselves. In such position, sideedges 12 are sealed along their length, generally creating a seal line14. Upon sealing, the layer 5 forms a pouch or pocket 10 with an opening15, two sealed side edges 12, and a fold of continuous material at thecentral fold line 13. In FIG. 2, the pouch of flexible plastic is mayalso be cut at its corners 16 near the central fold line 13 to reducebulk of the pouch 10 once it is positioned within the rigid containersidewalls of the container after expansion. However, in most cases suchcuts at corners 16 is not necessary, the excess material being easilyfolded later between bottom flaps of the container. The angle of cut forthe corners 16 appearing in FIG. 2, if such cuts are made, is thepreferred angle of about 45 degrees. The amount of material cut fromcorners 16, if such cuts are made, is the amount removed when cutting ata 45 degree angle at a distance from the corner 16 of the pouch 10 ofabout one-half the width of the narrower side panels of the outercontainer. FIG. 2 two shows the cut edges 17 where the corners 16 ofpouch 10 have been removed, and corner seal lines 18 as cut edges 17have been resealed to retain the water-tight and thermal properties ofthe pouch 10 prior to cutting corners 16. However, as noted above, thepouch corners may remain uncut in many applications with good effect.

Referring now to FIG. 3, a single piece of rigid or semi-rigid outercontainer material is shown cut into a blank 20 laying flat prior to itsassembly. Top flaps 21, bottom flaps 22, non-folding side panels 23,folding side panels 24, and a single end tab 25 are formed from therigid container material by cutting away excess material. At the end ofblank 20 opposite end tab 25, blank mating edge 31 is shown.

After cutting the container blank, or at the same time as the blank iscut, fold lines 9 are pressed into blank 20 between non-folding sidepanels 23 and folding side panels 24, to provide a means for easyfolding of all side panels against one another. As a result of pressingsuch fold or score lines into blank 20, top flaps 21 and bottom flaps 22may be easily folded at top flap fold lines 28 and bottom flap foldlines 29, and all side panels may be easily folded against one another.Additionally, fold or score lines 30 are pressed or scored into foldingside panels 24 of blank 20 midway between non-folding side panels 23, toallow easy folding of narrow side panels in half lengthwise (i.e., topto bottom in the expanded container). Additionally, end tab fold line 6is pressed or scored at the end of blank 20 to allow easy bending of endtab against the body of blank 20. Finally, bottom flap fold line 7 ispressed or scored into bottom flap 22 to allow easy bending along theedge of bottom flap 22, thereby allowing flap area 19 of bottom flap 22to bend for attachment to opposing bottom flap 22, and so allow flexureof bottom flaps one against the other after such attachment so that thecontainer of the present invention may be collapsed or expanded asneeded. Fold line 7 in this preferred embodiment is formed as two foldlines pressed into the blank close together, allowing the volume withinthis fold in the knockdown configuration to vary, thereby allowing thecontainer to easily fit around pouch material of different thickness.

FIG. 3 also shows first preferred areas 26 as preferred areas forapplication of fastening means, generally adhesive, which willeventually be used to attach the pouch of FIG. 2 to the container blank20. Preferred areas 26 are the most important areas to establish suchattachment, as these preferred areas correspond approximately to adistance from the edges 12 of the pouch 10 of about one-half the widthof the folding side panels 24 of the blank 20. In such position,attachment between non-folding side panels 23 and the pouch will allownon-folding side panels 23 to open the pouch 10 upon expansion of thecontainer prior to use. However, additional adhesive may be applied toother, secondary attachment areas 27, or even over the area of theentire area of the non-folding side panels 23 in some applications ifadditional strength is desired. Adhesive is also applied to attachmentarea 19 for attaching bottom flap 22 to opposing bottom flap 22.

When constructed as set forth in FIG. 3, a convenient method ofmanufacture of the outer blank 20 is disclosed, so as to make assemblywith pouch 10 possible with minimal expense and effort. In suchassembly, outer blank 20 is first cut as shown in FIG. 3, and adhesive(not shown), or an adhesive strip (not shown), is applied or secured tothe preferred areas 26, after which pouch 10 is set on blank 20 so thatthe pouch rests between folding side panel fold lines 30. In suchposition a mid-line of pouch 10, running from the mid point of opening15 to the mid point of fold line 13, is equidistant from such fold lines30. Pouch 10 is also positioned so that pouch fold line 13 rests at ornear bottom flap fold line 7. In such position the top edges 11 of pouch10 rest near the distal edge of top flap 21. By such placement, pouch 10is placed in contact with the adhesive or adhesive strip of thepreferred areas 26 near the edges of wider panels 23, and is therebysecured to such areas 26. In such position, pouch end edges 11 mayextend beyond top flaps 21, however pouch bottom at fold line 13 shouldnot extend beyond bottom fold line 7 of bottom flap 22.

After placement of pouch 10 as described above, the ends of blank 20 maybe folded across pouch 10 in such a way as to position end tab 25 overthe outside of mating edge 31, and fastening flap 25 may then be securedto mating edge 31 utilizing the same adhesive used to secure pouch 10 topreferred areas 26 of blank 20. After placement of pouch 10 as describedabove and folding of ends of blank 20 as described above, the distaledge of flap 22 and the fastening area 19 proximal to that edge, may befolded across the bottom edge 13 of pouch 10 in such a way as toposition fastening area 19 over the outside of the mating edge 8 ofopposing bottom flap 22 and fastening area 19 may then be secured tomating edge 8 utilizing the same adhesive used to secure pouch 10 topreferred areas 26 of blank 20. In this way, a single application ofadhesive may be used to secure the pouch 10 to blank 20 at preferredareas 26, to close blank 20 over pouch 10 during assembly to create atubular form, and to seal opposing bottom flaps 22 one to the otheralong bottom flap attachment area 19 to create a flexible bottom for thecontainer of the present invention.

In FIG. 4, the rigid or semi-rigid blank 20 is shown in perspectiveview, with pouch 10 placed in position as set forth above. In FIG. 4,pouch 10 rests between folding side panel fold lines 30, with pouchedges 12 on each side of pouch 10 resting near such fold lines 30. Insuch position a mid-line of pouch 10, running from the mid point ofopening 15 to the mid point of fold line 13, is equidistant from suchfold lines 30. Pouch 10 is also positioned so that pouch fold line 13rests at or near bottom flap fold line 7. In such position the top edges11 of pouch 10 rest near the distal edge of one of top flaps 21. By suchplacement, pouch 10 is placed in contact with the adhesive or adhesivestrip of the preferred areas 26 under pouch 10 (not shown) near theedges of wider panels 23 under pouch 10 (not shown) and is therebysecured to such areas 26. In such position, pouch end edges 11 mayextend beyond top flaps 21, or not, however pouch bottom at fold line 13should not extend beyond bottom fold line 7 of bottom flap 22. End tab25 is shown with its area for adhesive distal to end flap fold line 6,and preferred areas for adhesive 26 on non-folding side panels 23,however in FIG. 4 blank 20 has not yet been folded along fold lines 30,but rather remains in open position.

In FIG. 5, the rigid or semi-rigid blank 20 is shown in the sameperspective view of FIG. 4, with pouch 10 placed in position as before.However, in FIG. 4, blank 20 has been folded along narrower panel 24fold lines 30, and the ends of blank 20 have been fastened togetherutilizing end tab 25 affixed over and to the area adjacent blank matingedge 31 (not shown) of non-folding side panel 23. By such affixation, anangular tube of rigid or semi-rigid material capable of lying flat (asshown) is created, which tube may also be expanded into a rectangulartube shape (as shown in FIG. 7). Such expansion is accomplished by auser when a container is needed, by bending at fold lines 9 betweennon-folding side panels 23 and folding side panels 24. In FIG. 5, thetubular construction of the now folded blank 20 surrounds pouch 10, withpouch bottom fold 13 appearing between bottom flaps 22, and extendingapproximately up to bottom flap fold line 7. Top flaps 21 are attachedto the main body of the blank at fold lines 28, while bottom flaps 22are attached to the main body of the outer container at fold lines 29.The blank has been folded at fold lines 30, while additional fold lines9 (top fold line only is shown) allow expansion of the blank 20 into thetubular configuration.

In FIG. 6, the blank 20 is again shown, and again folded along foldlines 30, with additional fold lines 9, and end tab 25 secured tonon-folding side panel 23 near blank mating edge 31 (not shown) as inFIG. 5. In FIG. 6, however, bottom flap 22 underneath pouch 10 has beenfolded at bottom flap fold line 7 over the bottom fold 13 of pouch 10,and secured to opposing bottom flap 22 on the upper side of thecontainer. By such folding and securing, a flexible bottom for thecontainer is created which allows expansion and contraction of thecontainer as desired.

In FIG. 7, the rigid blank 20 is again shown viewed from its bottom, butin its expanded configuration, with bottom flaps 22 and bottom flap foldlines 29 nearest the viewer, and top flaps 21 and top flap fold lines 28away from the viewer. One fold line 30 is again apparent, however foldlines 9 are, in the expanded configuration apparent as the lines ofintersection between non-folding side panels 23 and folding side panels24. Pouch end edges 11 may are apparent extending beyond top flaps 21.However, pouch 10 is no longer apparent through the bottom of thecontainer, as interior bottom flaps 22 have been manipulated from theirfold down configuration to their expanded configuration. As interiorbottom flaps 22 have been fastened together along bottom flap attachmentarea 19 to create a flexible bottom, the bottom of the container is nowclosed, with pouch 10 on the interior, and exterior bottom flaps 22remaining to be folded into position and locked in place. In suchposition, and because of the previous attachment of pouch 10 to blank 20along attachment areas 26 (now shown), the pouch has followed thesidewalls 23 and 24 of the blank 20 in its expansion, thereby alsoexpanding pouch 10. The cut corners of pouch 10 have largely withdrawninto the container in FIG. 7, thereby saving volume within the containerand bulk when folding the remaining bottom flaps 22 into position overthe bottom of the container formed by the interior bottom flaps 22.However, as noted above, pouch 10 may also be formed without cuttingcorners 16, in which case the material forming such corners may besimply folded across the bottom formed by interior bottom flaps 22. Suchfolding over the bottom of the container will also generally result infolding the flaps of the folding sidewalls over the exposed bottomcorners of the inner pouch, which normally project from the interior ofthe contain out between the folding sidewalls and the now straightenedflaps of the non-folding sidewalls. A user may continue expansion byfolding exterior bottom flaps 22 over the bottom of the container, andlocking the exterior bottom flaps 22 into slots formed in interiorbottom flaps 22, or by sealing the exterior bottom flaps in position ortogether with tape or by other conventional means, a solidly constructedbottom for the container is formed which holds the container open, andready to receive articles for transport or storage.

Referring to FIG. 8, the rigid container of the present invention isagain shown in perspective, from the top, the blank 20 again fullyfolded at fold lines 9 and expanded to straighten fold line 30 offolding side panels 24. Pouch 10 again appears in expanded configurationas it has expanded with the expansion of the container wider sidewalls23, and top flaps 21 and pouch opening 15 appear open for receivingobjects. In its expanded configuration, the blank 20 has been opened upby bending at its fold lines 7, and straightening sidewalls 24 at foldlines 30. The pouch 10 appearing in FIG. 2 has followed the side wallsof the outer container 20 in FIG. 7, both at the top and the bottom ofthe pouch 10. Accordingly, pouch top edges 11 are pulled open by theadhesive at the interior corners of the outer container applied at thepreferred areas 26, shown in FIG. 3, creating opening 15 in the pouch 10through which objects may be passed for placement within the pouch 10.

Referring now to FIG. 9, the process of manufacturing the presentinvention is shown in flow chart form. In FIG. 9, rigid or semi-rigidmaterial is selected to form a blank 100 of suitable characteristics,and a blank is prepared. In such material, fold lines or score lines arepressed or scored 101, and a blank of the desired size and shape is thencut 102 as set forth above to produce a blank with fold lines or scorelines in the correct positions. The blank may be cut 103 and thenpressed or scored 104 as set forth above to produce fold lines or scorelines at the correct positions in the material of the blank. However,the most usual method with operations of this kind, and the preferredmethod within the scope of the present invention, is to accomplish thecutting of the blank 102/103 simultaneously with the scoring or pressingof the blank 101/104, “cookie cutter” fashion, utilizing a singlecutting and stamping die in a single step. Whether the blank is cutbefore, after, or with the placement of fold lines or score lines,attachment means, generally an adhesive, may then be applied 105 topreferred attachment means areas 26, or additionally to preferredattachment means 27, or additionally to one entire surface of each ofthe non-folding side panels 23.

Before or after the above series of steps taken to prepare a blank, orbefore or after any such steps, a flexible, waterproof, air-tight, andinsulated material is selected to form a pouch 120 of suitablecharacteristics, and a pouch is prepared. From such material, arectangle may be cut 121, and the rectangle folded 122. In thealternative, two squares or rectangles may be cut 123 having the samearea as the folded rectangle to produce a pouch having the same volume.Whether a single rectangle is cut 121 and folded 122 or two rectanglesare cut 123, the loose edges of the material so cut are matched 124, atleast approximately, for later sealing, or cutting and sealing. Once theedges of the material are matched 124, the manufacturer may elect tosimply seal the side edges 125 (or side and bottom edges in the case ofa pouch formed from two pieces of material), thereby creating a pouch 10with opening 15, and corners 16. In the alternative, the manufacturermay elect to cut the corners 126 of the pouch 10 after sealing, and sealthe cut edges where the corners were cut away 127, thereby creating thesame pouch but with shortened (or not) corners. The manufacturer may inthe alternative cut the edges and corners 128 of the materialsimultaneously 128 after matching edges 124, and seal the side edges andcut edges where the corners were cut away 129 if a pouch without cornersis desired.

Once a blank is prepared and a pouch is prepared using the above method,the pouch is placed on the blank 150 in the correct position as setforth above, between fold lines 30, and the pouch is pressed into theattachment means 151 of areas 26 (or so much attachment means as ispresent in areas 26, 27, and the remainder of non-folding side panel23). Once the pouch is securely affixed to the blank, the blank may thenbe folded 152 at side panel fold lines 30, so that end tab and matchingedge of the blank overlap, and end tab and the area at the end of theblank, near its matching edge may be fastened together 153, therebycreating an angular tubular arrangement of sidewalls. Once the tubulararrangement of sidewalls has been created, that longest bottom flaphaving an area for fastening 19, may then be folded 154 over the pouch10, and over the edge of opposing bottom flap 22, and the attachmentmeans of that area for fastening 19 used to fasten the first bottom flapto the opposing bottom flap 155.

1. A water-resistant container, comprising: a container having a firstfolding sidewall and a second folding sidewall, the first and secondfolding sidewalls being opposing container sidewalls, the first andsecond folding sidewalls each having two opposing edges creating widths,the first and second folding sidewalls having fold lines approximatelymidway between their opposing edges, the fold lines runningapproximately from the top of each of the first and second foldingsidewalls to the bottom of each of the first and second folding walls,the container having a first non-folding sidewall and a secondnon-folding sidewall, the first and second non-folding sidewalls beingopposing container walls, the first and second folding sidewalls affixedat two of their edges to two edges of the first and second non-foldingsidewalls to form a tubular section, the tubular section having a topend and a bottom end, the first end of the tubular section having aplurality of flaps attached thereto, the second end of the tubularsection having a plurality of flaps attached thereto, the first andsecond folding sidewalls and the first and second non-folding sidewallshaving interior surfaces facing the interior of the tubular section andexterior surfaces facing the exterior of the tubular section, theintersection of the edges of the first and second folding sidewalls withthe edges of the first and second non-folding sidewalls creating cornersof the container, the first and second non-folding sidewalls havingareas near the corners of the container, on the interior surfaces of thenon-folding sidewalls, for attachment means, and a pouch having aninterior, a first exterior side, a second exterior side, a bottom edge,a right edge, a left edge, a plurality of top edges forming a topopening, the pouch being formed from a flexible and water-resistantmaterial, the pouch residing within the tubular section of thecontainer, the right edge of the pouch residing near the fold line ofthe first folding sidewall and the left edge of the pouch residing nearthe fold line of the second folding sidewall, the top edges of the pouchextending from the top end of the tubular section at least a distanceequal to one-half the width of the folding sidewalls, the bottom edge ofthe pouch extending from the bottom end of the tubular section at leasta distance equal to one-half the width of the folding sidewalls.
 2. Thewater-resistant container of claim 1, further comprising means forattaching the first exterior side of the pouch to the attachment areasof the first non-folding sidewall, and means for attaching the secondexterior side of the pouch to the attachment areas of the secondnon-folding sidewall.
 3. The water-resistant container of claim 2,wherein the flexible and water-resistant material is also thermallyinsulative.
 4. The water-resistant container of claim 3, wherein theflexible, water-resistant, and thermally insulative material comprisesat least one layer of material having bubbles of gas entrapped therein.5. The water-resistant container of claim 4, wherein the flexible,water-resistant, and thermally insulative material further comprises atleast one layer of reflective material.
 6. The water-resistant containerof claim 5, wherein the means for attaching the pouch to the interiorsurfaces of the walls of the outer container comprises an adhesive. 7.The water-resistant container of claim 6, wherein the means forattaching the pouch to the interior surfaces of the walls of the outercontainer comprises a releasable adhesive.
 8. The water-resistantcontainer of claim 7, further comprising means for sealing the pouch topopening.
 9. The water-resistant container of claim 1, wherein theflexible and water-resistant material is also thermally insulative. 10.The water-resistant container of claim 9, wherein the flexible,water-resistant, and thermally insulative material comprises at leastone layer of material having bubbles of gas entrapped therein.
 11. Thewater-resistant container of claim 10, wherein the flexible,water-resistant, and thermally insulative material further comprises atleast one layer of reflective material.
 12. A thermally insulativecontainer, comprising: a container having a first folding sidewall and asecond folding sidewall, the first and second folding sidewalls beingopposing container sidewalls, the first and second folding sidewallseach having two opposing edges creating widths, the first and secondfolding sidewalls having fold lines approximately midway between theiropposing edges, the fold lines running approximately from the top ofeach of the first and second folding sidewalls to the bottom of each ofthe first and second folding walls, the container having a firstnon-folding sidewall and a second non-folding sidewall, the first andsecond non-folding sidewalls being opposing container walls, the firstand second folding sidewalls affixed at two of their edges to two edgesof the first and second non-folding sidewalls to form a tubular section,the tubular section having a top end and a bottom end, the first end ofthe tubular section having a plurality of flaps attached thereto, thesecond end of the tubular section having a plurality of flaps attachedthereto, the first and second folding sidewalls and the first and secondnon-folding sidewalls having interior surfaces facing the interior ofthe tubular section and exterior surfaces facing the exterior of thetubular section, the intersection of the edges of the first and secondfolding sidewalls with the edges of the first and second non-foldingsidewalls creating corners of the container, the first and secondnon-folding sidewalls having areas near the corners of the container, onthe interior surfaces of the non-folding sidewalls, for attachmentmeans, and a pouch having an interior, a first exterior side, a secondexterior side, a bottom edge, a right edge, a left edge, a plurality oftop edges forming a top opening, the pouch being formed from a flexibleand thermally insulative material, the pouch residing within the tubularsection of the container, the right edge of the pouch residing near thefold line of the first folding sidewall and the left edge of the pouchresiding near the fold line of the second folding sidewall, the topedges of the pouch extending from the top end of the tubular section atleast a distance equal to one-half the width of the folding sidewalls,the bottom edge of the pouch extending from the bottom end of thetubular section at least a distance equal to one-half the width of thefolding sidewalls.
 13. The water-resistant container of claim 12,further comprising means for attaching the first exterior side of thepouch to the attachment areas of the first non-folding sidewall, andmeans for attaching the second exterior side of the pouch to theattachment areas of the second non-folding sidewall.
 14. The thermallyinsulative container of claim 13, wherein the flexible andwater-resistant material is also water tight.
 15. The thermallyinsulative container of claim 14, wherein the flexible, water-resistant,and thermally insulative material comprises at least one layer ofmaterial having bubbles of gas entrapped therein.
 16. The thermallyinsulative container of claim 15, wherein the flexible, water-resistant,and thermally insulative material further comprises at least one layerof reflective material.
 17. The thermally insulative container of claim16, wherein the means for attaching the pouch to the interior surfacesof the walls of the outer container comprises an adhesive.
 18. Thethermally insulative container of claim 17, wherein the means forattaching the pouch to the interior surfaces of the walls of the outercontainer comprises a releasable adhesive.
 19. The thermally insulativecontainer of claim 18, further comprising means for sealing the pouchtop opening.
 20. The thermally insulative container of claim 12, whereinthe flexible and water-resistant material is also thermally insulative.